Method and apparatus for making liquid iron and steel

ABSTRACT

A carbonaceous-based metallizing method and apparatus wherein a metallic oxide is converted into a carbon-containing, metallized intermediate that is melted in an induction channel furnace to produce liquid metal from said metallic oxide. In the application of iron ore in the form of fines or concentrate, using low-cost coal will greatly reduce capital and operating costs by virtue of eliminating agglomeration of ore, cokemaking, and blast furnace operation. The liquid iron so produced is efficiently converted into steel in a steelmaking furnace such as a basic oxygen furnace (BOF), especially when it is physically integrated to the induction channel furnace wherein the liquid iron is directly poured into the integrated BOF by the induction channel furnace, producing low-cost steel, little heat loss, and minimum emissions.

INTRODUCTION

The present invention relates to the making of iron and steel and is animprovement over Applicant's U.S. Pat. No. 6,409,790 B1, issued on Jun.25, 2002, hereinafter referred to as the “referenced patent.”

This referenced patent discloses a method and apparatus for practicingcarbonaceous-based metallurgy, and in the specific case of making liquidiron, two distinct steps are involved. The first step comprises theformation of an iron/carbon product in a horizontal tubular reactorwherein a gas containing oxygen is injected from a horizontal lanceinserted from the discharge end of the horizontal reactor while the hotiron/carbon product (intermediate) formed is discharged into a verticalreactor. The second step comprises the melting of the iron/carbonproduct in the vertical reactor, called a “melter/homogenizer,” by meansof the injection of a gas containing oxygen using a vertical lance toconvert iron/carbon product into liquid iron which is fed into a holdingreservoir. Specifically, the instant invention relates to improvementsmade to the referenced patent as it relates to the making of liquid ironcomparable to liquid iron produced in a blast furnace, which is commonlyknown in the steel industry as “Hot Metal.”

BACKGROUND

The steel industry in March 1998 issued a comprehensive publicationentitled “Steel Industry Technology Roadmap,” and on page 11, it statesthe following:

-   -   The ultimate objective in the iron smelting area is to develop a        coal-based process that produces liquid iron directly from coal        and ore fines or concentrate. Liquid iron is preferred to solid        iron because there is no gangue and it retains its sensible        heat. Coal is obviously preferred over coke or natural gas        because of its abundance and lower cost. If possible, the use of        fines or concentrate will eliminate agglomeration costs. These        new processes should have a high smelting intensity or        productivity. High productivity and the elimination of        cokemaking and agglomeration will significantly reduce capital        costs.        In substance, the Roadmap's ultimate objective was, and still        is, to substitute several plants, shown within the blue        enclosure of Exhibit 1, with one single efficient plant. The        Applicant conceived the subject matter disclosed in the        reference patent as a solution to the ultimate objective of        producing liquid iron directly wherein coal and ore fines or        concentrate are used; a patent application was filed, and the        reference patent was issued.

To put the concept into practice, a pilot was constructed (Exhibit 2)and tests were initiated. A multitude of problems were discovered. Themost serious problems consisted of the following:

N^(o) 1. Sporadic explosions caused by super-heated steam generated fromwater leakage from the melt-down of the stainless steel outer tube(sheath) at the copper tip of the water-cooled, oxygen injection lance(Exhibit 3), which endangered operating personnel, one of whomexperienced severe burns, necessitating a hospital stay. To prevent themelting of the stainless sheath, steps were taken to increase the sizeof the copper tip. Unfortunately, excessive build-up at the tip of thelance occurred (Exhibit 4), resulting in destroying the flow pattern ofthe oxygen.

N^(o) 2. The uniform flow of the gas containing oxygen from the tip ofthe lance is most critical in order to produce a uniform product, aniron/carbon intermediate of some 50% metallization with about 6% carbonis suitable for conversion into carbon-saturated liquid iron of blastfurnace specification. The problems caused by the build-up at the tip ofthe lance included premature melting, over-oxidation, too low inmetallization, and completely unreduced feed material:

N^(o) 3. Excessive heat loss occurred within the horizontal reactor,especially toward its discharge end, caused by the cooling effect fromthe water-cooled lance.

N^(o) 4. Build-up at the discharge end of the horizontal reactor itselfpersisted (Exhibit 5), resulting in a physical blockage that preventedthe advancement of the contents of the horizontal reactor by means ofthe pushing ram of the charger, thus forcing unscheduled shutdowns.

N^(o) 5. Build-up downstream of the horizontal metalizing reactor andupstream of the storage was also experienced in the vertical sectionwhere the homogenizer/melter would be located, causing shutdowns thatentailed moving equipment to provide access to poke hot, built-upmaterial with a bar to unplug the build-up; Exhibit 6.

N^(o) 6. Iron/carbon intermediate that was fed to the melting furnace,being lighter than the liquid iron, would float on top of the moltenbath (Exhibit 7) and dwell there, instead of entering into solution withthe metal in the molten bath, such flotation of intermediate preventingthe rapid and complete conversion of the intermediate into liquid iron.

In addressing problems N^(o) 1, N^(o) 2, and N^(o) 3, it was decided torelocate the injection lance to be introduced from the cold end throughthe charger of the horizontal metallizing reactor, as shown in Exhibit8, together with increasing the pressure of injection of the gascontaining the oxygen to create a forceful jet from the tip of the lanceto reach all the way to the discharge end of the horizontal metalizingreactor, with the tip of the lance being located where the temperatureof the iron ore and ash are below their incipient fusion. This requiredthe construction of a new charger (Exhibit 9), wherein a provision wasmade for the lance to pass through the center of the mandrel, resultingin a structure of the lance being disposed through the mandrel and themandrel through the pushing ram.

In addressing problem N^(o) 4, which relates to the blockage created bybuild-up at the discharge end of the metallizing reactor, the newcharger was constructed structurally more robust than the initial one,and also the hydraulic pressure was raised by adding a booster hydraulicpump with new controls (Exhibits 10A and 10B) to increase the pushingforce of the new charger in order to surmount blockage.

In addressing problem N^(o) 5, to prevent build-up downstream of themetalizing reactor and upstream of the storage, it was decided tocompletely eliminate the homogenizer/melter (numeral 11), described inthe referenced patent, and perform the melting of the iron/carbonintermediate in an induction channel furnace (ICE) as that made by AjaxMagnethermic, with certain modifications as would be described in detailhereinafter, to serve both as a melter as well as storage of liquidiron.

In addressing the issue of the intermediate flotation on top of themolten bath, a vertically oscillating mechanical dunker was developed(Exhibit 11A) which was equipped with a graphitic block (Exhibit 11B)which is adapted to force the floating intermediate to be submergedbelow the level of the high-temperature bath where the carbon in theintermediate completes the reduction of the unreacted oxides of iron,namely, Fe₂O₃, Fe₃O₄, and FeO, which have not reacted in the horizontalmetallizing reactor.

With the changes made, the Applicant was successful in overcoming theproblems mentioned hereinbefore and producing an acceptable intermediateinto which carbon from the coal is integrally imbedded within themetallized iron made from ore fines or concentrate in the horizontalmetalizing reactor (Exhibit 12).

Further, two valuable gases are co-produced: one during themetallization of the iron ore in the horizontal metallizing reactor anda second during the melting of the intermediate (Exhibit 13).

To summarize the above, the Applicant, in effect, has invented a methodand apparatus adapted to accept various proportions of ore and coal andyet produce a liquid iron (Exhibit 13) by way of producing anintermediate whose composition is quite suitable to be converted toliquid iron that can be subsequently converted into low-cost steel.

OBJECTIVE OF THE INVENTION

The main object of this invention is to produce liquid iron directlyfrom ore fines and concentrate using low-cost coal consistent with theUltimate Objective stated in the Steel Industry Technology Roadmap ofMarch 1998, mentioned above.

Another object of the present invention is to provide an efficientmethod and apparatus to carry out same for converting an iron ore andcoal mix into liquid iron at an efficiency greater than the conventionalprocess of making liquid iron in a blast furnace that uses coke and ironore pellets.

Therefore another object of the instant invention is to provide a methodand apparatus that greatly reduce heat loss when compared with theconventional process of making liquid iron in a blast furnace that usescoke and iron ore pellets.

Still another object of the instant invention is to provide a method andapparatus that greatly reduce emissions when compared to conventionalprocesses that feed pellets, sinter, and coke into a blast furnace,which in turn is a major emitter of carbon dioxide (CO₂).

Further another object of the present invention is making an inductionchannel furnace (ICF) more efficient while still protecting its liningby providing dunking means which assist in submerging an iron/carbonintermediate into the molten iron bath in the ICF in order to expediteits reaction and cause it to blend with the constituents in the molteniron bath to result in its rapid liquifaction and assimilation withinthe molten iron bath.

Further still another object of the present invention is to physicallyintegrate an induction channel furnace (ICF) to a steelmaking furnace,such as to a basic oxygen steelmaking furnace or to an electric arcsteelmaking furnace, known in the industry as BOF and EAF, respectively,but by way of example, the description that follows will disclose theintegration of the ICF to the BOF, the ICF being adapted to convert aniron and carbon intermediate into molten iron while the BOF convertsmolten iron and scrap into steel. The ICF and the BOF are joinedtogether structurally in such a way as to result in a hybrid,dual-purpose configuration that reduces capital and operating costs,increases efficiency, and minimizes emissions.

Further yet another object of the present invention consists inproviding a physical interconnection between the ICF and the BOF toenable the direct pouring of molten iron directly from said ICF in saidBOF by revolving both said ICF and said BOF radially withoutnecessitating the use of a crane.

It is still another object of the present invention to provide an ICFper se in the case of making molten iron only in situations where animproved method of iron making is required without the production ofsteel.

It is therefore another object of the present invention to provide amethod and apparatus that can convert carbon dioxide (CO₂), a greenhousegas, into a useful product such as fertilizer.

Other objects of this invention will appear from the followingdescription and appended claims. Reference is made to the accompanyingdrawings which describe certain apparatus structures to practice thismethod of making an iron/carbon intermediate which is converted toliquid iron, which is subsequently converted into steel. It is to beunderstood that the method and apparatus disclosed herein are notlimited solely to the processing of iron-bearing ore, as the inventioncan also be applied to other non-iron bearing ores.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the plant to directly make liquid iron from coal andore fines or concentrate.

FIG. 2 represents the metallizing reactor in perspective and in section,and FIG. 2A shows the actual iron/carbon intermediate with the carbonbeing physically imbedded in the metallized iron.

FIG. 3 illustrates in perspective a battery of metallizing reactors thatproduce the intermediate.

FIG. 4 is a close-up and partial view of the induction melting furnaceswith the intermediate delivery system.

FIG. 5 illustrates a side elevation of the plant, which includes gascleanup and the co-production of fertilizer (oxamide) from a gascontaining CO₂.

FIG. 6 illustrates the integration of a steelmaking furnace, which iscommonly known as a basic oxygen furnace (BOF), to an ironmakingfurnace, which is commonly known as an induction channel furnace (ICF).

FIG. 7 through FIG. 18 show the various operating steps of producing theliquid iron and its conversion into steel, which are simultaneouslycarried out with the iron liquid produced in the ICF and the steel inthe BOF.

Before describing in detail the present invention, it is to beunderstood that this invention is not limited to the details orarrangement of the parts illustrated in the attached drawings, as theinvention can be operative by using other embodiments. Also, it is to beunderstood that the terminology herein contained is for the purpose ofdescription and not limitation.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates conceptually a plant consisting of two batteries,marked 20(a) and 20(b), with each comprising several identicalmetalizing reactors, one of which is marked by numeral 21, two meltingfurnaces marked A and B, and conveyors that feed hot iron/carbonintermediate made in the metalizing reactors to the two meltingfurnaces.

In describing the plant in more detail, the Applicant will describe onlybattery 20(a) and furnace A, since the two batteries and the twofurnaces are identical.

Beneath each battery, two conveyors, marked by numerals 22(a) and 23(a),are disposed, with conveyor 22(a) being fixed, and conveyor 23(a) isadapted to travel as a shuttle conveyor. Shuttle conveyor 23(a) isadapted to travel not only to furnace A, but also all the way to the endof furnace B, in order to provide redundancy. Furnace A possesses threeidentical feed openings, marked by numeral 24, equally spaced along thelength of both furnaces to enable shuttle conveyor 23(a) to distributehot iron/carbon intermediate along the length of furnace A as well asfurnace B. At the head of shuttle conveyor 23(a), a dunker, marked bynumeral 25, is disposed to immerse into the molten bath, iron/carbonintermediate that is fed into furnace A or furnace B. It is to be notedthat shuttle conveyor 23(b) can service both furnace A and furnace B.

Referring to FIG. 2, it illustrates iron/carbon metallizer reactor 21 inperspective and in section, with feed-hopper 26 adapted to feed coal andfeed-hopper 27 to feed a mix of ore and coal. Numeral 28 represents thecharger, which is made-up of mandrel 29 and main ram (pusher) 30, withlance 31 being disposed through the center of mandrel 29 withpenetration at the charging end of reactor 21. The coal core is the darkcolored material denoted by numeral 32 through which lance 31 passes andannulus 33, which is made-up of an iron-and-coal mix, fully surroundscoal core 32. The discharge of reactor 21, which consists of a hotradiant chamber, is marked by numeral 34; it possesses an inlet port 35for mounting a start-up burner. A slide gate provided downstreamdischarge chamber 34, marked by numeral 35(a), serves as a controlfeeding apparatus to service a surge containment vessel from metalizingreactor 21 into main conveyor 22(a) (shown in FIG. 1) at a predeterminedsequence, since conveyor 22(a) receives iron/carbon intermediate fromseveral metalizing reactors. It is to be noted that metalizing reactor21 is lined with insulation and refractory material with heating fluesbuilt in the refractories to radiate heat into reactor 21 in order toprovide thermal energy to heat annulus 33 bi-directionally. The heatingflues are not shown, as it is commonly used in industry, and they arealways encased in a steel shell marked by numeral 39. FIG. 2A representsthe actual structure of the iron/carbon intermediate which clearly showscarbon which originated from coal, interspersed in iron which originatedfrom the ore. Such intermediate is the feedstock to produce liquid ironby way of melting it. During metallization of the iron ore with coal, ahydrogen (H₂) rich gas is generated; this gas, which is quite valuableas an energy source, leaves through exit port 37.

Referring to FIG. 3, it illustrates battery 20(a) with most of itscomponents described in FIG. 1 and FIG. 2, except for numeral 40 whichrepresents the distribution conveyors of feed into feed-hoppers 26 and27. The other equipment is represented as follows: The skip hoist todeliver feed from ground level by numeral 41, the furnace exhaustsuction dud by numeral 42, the exhauster by numeral 43, flue gasinjection manifold by numeral 44, and sizing screen by numeral 45 whichseparates the screenings from the iron/carbon intermediate prior tobeing fed into furnace A to minimize dust emissions during the feed ofthe intermediate.

Referring to FIG. 4, it illustrates part of battery 20(a), inductionchannel furnace A, and part of furnace B. In addition to what wasdescribed in previous Figures, furnace A is shown with a front partmissing to illustrate the internals of the furnace with a graphiteimmersion block marked by numeral 46 at the left side of furnace A.Other parts include the upper component of dunker 25 that forces theiron/carbon intermediate floating on top of molten iron which isimmersed into molten bath 72, swivel joint 47 which permits the rotationof the furnace while still continuously extracting combustion gases fromwithin furnace A, the furnace hearth 48, and the combustion of CO abovethe hearth being released from the reaction of oxygen from the ironoxides with carbon contained in the immersed iron/carbon intermediate.

Referring to FIG. 5, it represents a side elevation of the plant whereinconveyor 22(a) and conveyor 23(a) have been replaced by a stand pipemarked by numeral 49 followed by valves 50 and 51 controlling the feedof iron/carbon intermediate directly into induction channel furnace Aand exhausting the flue gas (N₂+CO₂) from furnace A to the bottom ofstand pipe 49. A piping system denoted by numeral 52 connects to heatexchanger 53 which feeds relatively cold gas containing mercury intocleanup bed 54(a) or cleanup bed 54(b); these two beds, which alternatein usage, contain activated carbon to extract mercury from the gas.Downstream from exchanger 53, a desulfurizer 55 forms the lower part ofa hot-gas cleanup with a sorbent regenerator 56 disposed abovedesulfurizer 55. Two reactors 59(a) and 59(b) are disposed downstream ofdesulfurizer 55 to serve as converters of carbon monoxide (CO) tocyanogen, and downstream of sorbent regenerator a sulfur recovery systemmarked by numeral 57; it serves to recover the sulfur in elemental form,a marketable commodity. A second heat exchanger denoted by numeral 58conditions the desulfurized gas. Reactors 59(a) and 59(b) alternate frombeing a producer of cyanogen to a regenerator of the catalyst.Downstream of reactors 59(a) and 59(b) a liquifier marked by numeral 60is provided; it is followed by separator 61, and pump 62 which elevatesthe cyanogen to be hydrated in column 63 to form oxamide, a slow-releasefertilizer. A settling tank 64 is disposed upstream of filter press 65while drier 66 follows filter press 65, and stacker 67 transports thefinal product as a marketable fertilizer to storage 68.

FIG. 6 illustrates the integrating of steelmaking to ironmaking by meansof a BOF to an ICF, both referenced in the Objective section in thisdisclosure; it is feasible to consolidate the following three steps in asingle, low-cost, efficient, physically integrated Method consisting of:

-   -   Metallization of iron ore consisting of fines or concentrate        with coal forming an intermediate;    -   Melting the intermediate producing liquid iron; and    -   Blowing the liquid iron with oxygen producing steel.

Since the method of metallization and melting has been described indetail above, FIGS. 7 to 18 will describe the steps of feeding theiron/carbon intermediate, melting it into liquid iron and producing thesteel.

FIG. 7 illustrates shuttle conveyor 23(a) or conveyor 23(b) feedingiron/carbon intermediate into the ICF with material floating on themolten bath marked by numeral 71 while oxygen is being blown within theBOF by means of a vertical lance 69 converting the iron into steel withfumes being collected in hood 70; a hoist marked by numeral 73 serves toraise and lower lance 69.

FIG. 8 is the same as FIG. 7, except for dunker 25 positioning graphiticblock 46 over the intermediate which is still floating over the moltenbath. FIG. 9 shows that graphitic block 46 has immersed the floatingintermediate into bath 72.

FIG. 10 illustrates the pouring of the slag from the BOF into pot 75while using a stopper rod denoted by numeral 74 to prevent the flow ofliquid iron from the ICF by virtue of the ICF being in a tiltedposition. FIG. 11 illustrates tapping of the steel from the bottom ofthe BOF into ladle 76 using slide gate 77. It is to be noted that theslagging and tapping of the BOF may be effected by other configurations.

FIG. 12 illustrates the heat in the BOF has been tapped and the droppingof a tapping-hole sealing material 78 into the BOF tap hole marked bynumeral 79. FIG. 13 illustrates sealing material 78 in the process offilling tap hole 79, and FIG. 14 shows the tap hole 79 to have beensealed.

FIG. 15 illustrates the slagging of the ICF by tilting the ICFcounter-clockwise, with slag produced from melting the intermediatemarked by numeral 80, being poured out from the ICF. FIG. 16 illustratesthe tilting of the ICF clockwise to enable the charging of the BOF withscrap, which is marked by numeral 81, by means of chute 82 with stopperrod 74 being in the down position to prevent molten iron from flowingfrom the ICF into the BOF during the charging of the scrap. FIG. 17shows that while the ICF and the BOF are in the tilted position, stopperrod 74 is in the raised position allowing the liquid iron, marked bynumeral 83, to flow from the ICF into the BOF, dispensing apredetermined charge of liquid iron on top of scrap 81. At this pointthe ICF is rotated from its tilted position to the erect position, hood70 rotated over the mouth of the BOF, oxygen lance 73 hoist lowered intothe BOF to begin converting the liquid iron into steel by blowing oxygenfrom lance 69 while conveyor 23(a) or (b) positioned over charging hole24 of the ICF, proceeds the feeding of iron/carbon intermediate into theICF to melt it while the liquid iron and the scrap are being convertedinto steel, as illustrated in FIG. 18 which is the same as FIG. 7, whichillustrates the same functions of feeding iron/carbon intermediate byconveyor 23(a) or (b), melting it into liquid iron in the ICF to formbath 72 and converting the liquid iron and scrap into steel, while ironore fines or concentrate undergo metallization with coal in metalizingreactor 21, shown and described in FIGS. 1 through 5, inclusive.

With respect to the application of this invention to the non-ferrousmetals, variations to that which is disclosed herein, can take place;however, the intention is not to depart from the spirit of thisdisclosure. All in all, it is submitted, herein that the instantinvention provides major improvement over conventionalpractice/metallurgy, which can use low-cost raw materials, and which isenergy efficient and environmentally friendly, while requiring lowcapital investment.

1. A method for thermally processing a metallic oxide with acarbonaceous material in one or more horizontal chambers wherein eachhorizontal chamber has a charging end and a discharging end, adapted toproduce a hot carbon containing metallized product which is subsequentlymelted in a melter to produce a hot liquid metal and valuable fuelgases, comprising the following steps: feeding a carbonaceous materialwhich contains volatile matter at the charging end of said chamber insuch a way as to be sealed to the atmosphere; feeding a mix made-up of acombination of a metallic oxide and carbonaceous material into saidchamber in such a way as to be sealed to the atmosphere; combusting aportion said carbonaceous material in said chamber with an oxidant in asuppressed mode to produce reducing gases to reduce said metallic oxideto result in the formation of a hot, carbon-rich metal characterized asan intermediate; discharging said intermediate into a vertical chamberwhich is equipped with a control valve to enable the dispensation ofsaid intermediate in a controlled sequence into a melting furnace;melting said intermediate in said furnace to complete the reduction ofsaid metallic oxide to produce a molten bath of liquid metal togetherwith a fuel gas evolving from said bath; combusting said fuel gas abovesaid bath to radiate thermal energy back to said bath to increase theefficiency of the melting furnace while producing products ofcombustion, including CO₂; exhausting said products of combustion fromsaid melting furnace and directing them to the bottom of said verticalchamber to rise through it while contacting said hot, carbon-richintermediate to convert CO₂ to CO; and utilizing said CO to produce avaluable by-product.
 2. The method as set forth in claim 1 wherein thestep of feeding a carbonaceous material which contains volatile matteris characterized by feeding it in such a way as to form a core withinsaid horizontal chamber;
 3. The method as set forth in claim 2 whereinsaid core is characterized by having a bore through said core toaccommodate the insertion of an oxidant injection lance through saidbore.
 4. The method as set forth in claim 3 wherein said lance isinserted from the charging end of said horizontal chamber;
 5. The methodas set forth in claim 2 wherein said core is surrounded by an annulusmade-up of a mix consisting of carbonaceous material and a metallicoxide.
 6. The method as set forth in claim 2 wherein said core ismade-up of coal.
 7. The method as set forth in claim 5 wherein saidannulus is made up of coal and a metallic oxide.
 8. The method as setforth in claim 7 wherein said metallic oxide is iron ore in the form offines or concentrate.
 9. The method as set forth in claim 2 wherein saidcore is combusted under suppressed condition by means of a lanceinjecting an oxidant to produce reducing gases to serve in themetallization of an iron oxide.
 10. The method as set forth in claim 1wherein the step of melting said intermediate in said furnace tocomplete the reduction of said metallic oxide to produce a molten bathis further characterized by said bath being made-up of liquid ironproduced in an induction channel furnace, called for short “ICF.” 11.The method as set forth in claim 10 wherein said liquid iron isconverted into steel in a basic oxygen furnace, called for short “BOF.”12. The method as set forth in claim 11 wherein said BOF is physicallyconnected to an ICF, with both furnaces operating in an integratedprocedure wherein the ICF would be melting intermediate to produceliquid iron; the BOF converting the liquid iron into steel, with theliquid-iron step comprising the direct feeding from the ICF into the BOFoccurring after the completion of the tapping of the previous steel heatfrom the BOF.
 13. The method as set forth in claim 12 wherein the stepof both furnaces operating in an integrated procedure is furthercharacterized by said ICF being fed with intermediate produced in abattery of horizontal metallizing reactors and delivered to the ICF bymeans of conveyors.
 14. The method as set forth in claim 13 wherein twoinduction channel furnaces are provided and equipped with duplicateconveyors to insure redundancy.
 15. The method as set forth in claim 12wherein the step comprising the direct feeding from the ICF into the BOFis effected in a controlled manner by means of a valve characterized asa stopper rod, which insures that proper flow is synchronized during therotation of the ICF.
 16. The method as set forth in claim 1 wherein thestep of utilizing said CO to produce a valuable by-product ischaracterized by the step of cleaning said CO.
 17. The method as setforth in claim 16 wherein said CO is converted to cyanogen after itscleanup.
 18. The method as set forth in claim 17 wherein said CO isconverted to cyanogen is characterized by hydrating said cyanogen tooxamide, a slow-release fertilizer.
 19. The method as set forth in claim16 wherein the step of cleaning said CO is further characterized byremoving mercury from said CO.
 20. The method as set forth in claim 1wherein the step of discharging said intermediate into a verticalchamber which is equipped with a control valve to enable thedispensation of said intermediate in a controlled sequence into amelting furnace is further characterized by providing a dunker adaptedto immerse floating intermediate into the bath of said furnace toexpedite the melting of the intermediate to result in increasing theproductivity of liquid iron from said melting furnace.
 21. Apparatus forthermally processing a metallic oxide with carbonaceous material toproduce liquid metal comprising: a horizontal metallizing reactor havinga charging end and a discharging end equipped with a pushing ram throughwhich a mandrel is disposed, with said mandrel having a bore throughwhich an injection lance is disposed in such a way as to inject anoxidant from the charging end towards the discharging end of saidreactor to produce an intermediate made from ore and carbonaceousmaterial; a mechanism disposed downstream of the discharge end of saidreactor capable of controlling the feed of said intermediate materialinto a melting furnace wherein said intermediate is converted into aliquid metal while producing a gas within said furnace; oxidantinjection means adapted to combust said gas in said furnace to make saidfurnace more efficient in converting said intermediate into liquid metalby increasing the thermal energy input in said furnace; suction meansadapted to extract products of combustion containing CO₂ from saidfurnace; means for converting said CO₂ into CO; means for cleaning upsaid CO; and means for converting said CO into a useful product.
 22. Theapparatus defined in claim 21 including downstream of said meltingfurnace, a steelmaking furnace to convert the liquid metal into steel.23. The apparatus defined in claim 22 wherein said steelmaking furnaceis physically integrated to said melting furnace which is adapted todirectly feed liquid metal directly from said melting furnace into saidsteelmaking furnace to increase efficiency, minimize heat loss, andreduce emissions.
 24. The apparatus defined in claim 21 possessing meansadapted to submerge intermediate material floating on top of liquidmetal in said melting furnace by means of a dunker capable of exercisingan up-and-down motion to forcefully push the floating intermediate belowthe level of the liquid metal contained in the melting furnace.